Manufacture of lozenge product with radiofrequency

ABSTRACT

The present invention features a process for making a lozenge product including the steps of forming a powder blend containing an amorphous carbohydrate polymer into the desired shape of the lozenge product and applying radiofrequency energy to the shape for a sufficient period of time to soften or melt said amorphous carbohydrate polymer to fuse the shape into said lozenge product.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.12/887,575, filed Sep. 22, 2010, now U.S. Pat. No. 8,343,533, whichapplication claims priority of the benefits of the filing of U.S.Provisional Application Ser. No. 61/245,315, filed Sep. 24, 2009, U.S.Provisional Application Ser. No. 61/255,582, filed Oct. 28, 2009, U.S.Provisional Application Ser. No. 61/314,629, filed Mar. 17, 2010, andU.S. Provisional Application Ser. No. 61/358,167, filed Jun. 24, 2010.The complete disclosures of the aforementioned related U.S. patentapplications are hereby incorporated herein by reference for allpurposes.

BACKGROUND OF THE INVENTION

Lozenges are typically produced using a boiled mixture of sugar and/orcorn syrup, wherein the mixture is heated and melted. However, certainmaterials are not compatible with such methods that use high heat for asignificant amount of time, such as heat sensitive active ingredientsand volatile flavor and sensate components. Such lozenges also have thedisadvantage of using very moisture sensitive materials or retain alarge amount of latent or bound water upon cooling into the finallozenge form. This may require expensive packaging which has lowmoisture permeability or the use of external desiccants. In addition,latent moisture can be an issue for certain active ingredients,particularly pharmaceutical active ingredient, where the formation ofdegradant compound can be accelerated upon stability.

Thus, there is a need for making lozenges which does not utilize thehigh temperatures and/or high amount of water content used in thetypical boiling process.

SUMMARY OF THE INVENTION

In one aspect, the present invention features a process for making alozenge product including the steps of forming a powder blend containingan amorphous carbohydrate polymer into the desired shape of the lozengeproduct and applying radiofrequency (“RF”) energy to the shape for asufficient period of time to soften or melt said amorphous carbohydratepolymer to fuse the shape into said lozenge product.

In other aspects, the present invention features lozenge productsmanufactured by such process and the use of lozenge products.

Other features and advantages of the present invention will be apparentfrom the detailed description of the invention and from the claims.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A-F are cross-section, side views of an embodiment of theinvention showing the manufacture of lozenge shape 4 a from powder blend4 within die platen 2.

FIGS. 2A-H are cross-section, side views of an embodiment of theinvention showing the manufacture of a bilayer lozenge 12 from powderblends 10 and 11 within die platen 2.

FIGS. 3A-G are cross-section, side views of an embodiment of theinvention showing the manufacture of lozenge 40 containing preformedinserts 30 and 31 from powder blend 20 within die platen 2.

FIGS. 4A and 4B are a perspective view of a rotary indexing machine 195.

FIGS. 5A and 5B are top views of the rotary indexing machine 195 in thedwell position.

FIGS. 6A and 6B are section views of the lower forming tool assembly 110in the start position of the manufacturing cycle.

FIG. 7 is a section view through the RF station rotary indexing machine195 prior to compacting powder blend 101.

FIG. 8 is a section view through the RF station rotary indexing machine195 prior showing the manufacture of lozenges 101 a.

FIG. 9 is a section view through lozenge ejection station 160 beforelozenges 101 a have been ejected.

FIG. 10 is a section view through lozenge ejection station 160 afterlozenges 101 a have been ejected into blister 190.

FIGS. 11A-D are cross sections of alternate embodiments of forming toolsand the die platen.

FIGS. 12A-D are cross sections of alternate embodiments of forming toolsand the die platen.

FIG. 13A is a cross section of forming tools having a wave-shapedsurface.

FIG. 13B is a perspective view of forming tools having a wave-shapedsurface.

FIG. 14 is a cross section of forming tools having protrusions at thesurface.

DETAILED DESCRIPTION OF THE INVENTION

It is believed that one skilled in the art can, based upon thedescription herein, utilize the present invention to its fullest extent.The following specific embodiments can be construed as merelyillustrative, and not limitative of the remainder of the disclosure inany way whatsoever.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention belongs. Also, all publications, patentapplications, patents, and other references mentioned herein areincorporated by reference. As used herein, all percentages are by weightunless otherwise specified.

As discussed above, in one aspect, the present invention features aprocess for making a lozenge product including the steps of forming apowder blend containing an amorphous carbohydrate polymer into thedesired shape of the lozenge product and applying RF energy to the shapefor a sufficient period of time to soften or melt said amorphouscarbohydrate polymer to fuse the shape into said lozenge product.

Powder Blend

As discussed above, the lozenge shape is manufactured by forming apowder blend containing an amorphous carbohydrate polymer and optionallynicotine and/or other pharmaceutically active agent(s) and/orexcipients. Examples of such excipients include, but are not limited to,glidants, lubricants, sweeteners, flavors and aromatics, enhancers,coloring agents, preservatives, vitamins, minerals, fluoride, and toothwhitening agents, and mixtures thereof. One or more of the aboveingredients may be present on the same particle of the powder blend.

Suitable lubricants include, but are not limited to, long chain fattyacids and their salts, such as magnesium stearate and stearic acid,talc, glycerides waxes, and mixtures thereof.

Suitable glidants include, but are not limited to, colloidal silicondioxide.

Examples of sweeteners include, but are not limited to, synthetic ornatural sugars; artificial sweeteners such as saccharin, sodiumsaccharin, aspartame, acesulfame, thaumatin, glycyrrhizin, sucralose,dihydrochalcone, alitame, miraculin, monellin, and stevside; sugaralcohols such as sorbitol, mannitol, glycerol, lactitol, maltitol, andxylitol; sugars extracted from sugar cane and sugar beet (sucrose),dextrose (also called glucose), fructose (also called laevulose), andlactose (also called milk sugar); isomalt, salts thereof, and mixturesthereof.

Examples of flavors and aromatics include, but are not limited to,essential oils including distillations, solvent extractions, or coldexpressions of chopped flowers, leaves, peel or pulped whole fruitcomprising mixtures of alcohols, esters, aldehydes and lactones;essences including either diluted solutions of essential oils, ormixtures of synthetic chemicals blended to match the natural flavor ofthe fruit (e.g., strawberry, raspberry and black currant); artificialand natural flavors of brews and liquors, e.g., cognac, whisky, rum,gin, sherry, port, and wine; tobacco, coffee, tea, cocoa, and mint;fruit juices including expelled juice from washed, scrubbed fruits suchas lemon, orange, and lime; spear mint, pepper mint, wintergreen,cinnamon, cacoe/cocoa, vanilla, liquorice, menthol, eucalyptus, aniseedsnuts (e.g., peanuts, coconuts, hazelnuts, chestnuts, walnuts, colanuts),almonds, raisins; and powder, flour, or vegetable material partsincluding tobacco plant parts, e.g., genus Nicotiana, in amounts notcontributing significantly to the level of nicotine, and ginger.

Examples of coloring agents include, but are not limited to, dyes beingapproved as a food additive.

Amorphous Carbohydrate Polymer

The powder blend/lozenge shape/lozenge product contains at least oneamorphous carbohydrate polymer. What is meant by an “amorphouscarbohydrate polymer” is a molecule having a plurality of carbohydratemonomers wherein such molecule has a crystallinity of less than 20%,such as less than 10%, such as less than 5%. Examples of amorphouscarbohydrate polymers include, but are not limited to hydrogenatedstarch hydrolysate, polydextrose, and oligosaccharides. Examples ofoligosaccharides include, but are not limited to,fructo-oligosaccharide, galacto-oligosaccharide malto-oligosaccharide,inulin, and isolmalto-oligosaccharide.

In one embodiment, the amount of amorphous carbohydrate polymer in thepowder blend/lozenge shape/lozenge product is from about 50 percent toabout 99.9 percent, by weight, such as from about 80 percent to about 95percent by weight.

In one embodiment the powder blend/lozenge shape/lozenge productcontains less than about 20 percent by weight of crystalline material,such as less than 10 percent, such as less than 5 percent, such as none.In one embodiment the lozenge is substantially free of isomalt.

Nicotine Compound

In one embodiment, the powder blend/lozenge shape/lozenge productcontains a smoking cessation compound(s) such as: nicotine and/ormetabolites thereof, such as cotinine, nicotine N′-oxide, nornicotine,(S)-nicotine-N-β-glucuronide or salt thereof (hereinafter “nicotinecompound”); varenicline, bupropion, nortriptyline, doxepin, fluoxetine,imipramine, moclobemide, conotoxinMII, epibatidine, A-85380, lobeline,anabasine, SIB-1508Y, SIB-1553A, ABT-418, ABT-594, ABT-894, TC-2403,TC-2559, RJR-2403, SSR180711, GTS-21, and/or cytisine or salts thereof.The smoking cessation compound (e.g., nicotine compound) may be presentin the powder blend and/or the optional coating.

Numerous nicotine salts are known and may be used. Examples include, butare not limited to, formic (2:1), acetic (3:1), propionic (3:1), butyric(3:1), 2-methylbutyric (3:1), 3-methylbutyric (3:1), valeric (3:1),lauric (3:1), palmitic (3:1), tartaric (1:1) and (2:1), citric (2:1),malic (2:1), oxalic (2:1), benzoic (1:1), gentisic (1:1), gallic (1:1),phenylacetic (3:1), salicylic (1:1), phthalic (1:1), picric (2:1),sulfosalicylic (1:1), tannic (1:5), pectic (1:3), alginic (1:2),hydrochloric (2:1), chloroplatinic (1:1), silcotungstic (1:1), pyruvic(2:1), glutamic (1:1), and aspartic (1:1) salts of nicotine.

In one embodiment, the nicotine compound is bound to a resin (e.g., apolyacrylate resin), zeolite, or cellulose or starch microsphere.Examples of cation exchange resins include, but are not limited to,Amberlite IRC 50 (Rohm & Haas), Amberlite IRP 64 (Rohm & Haas),Amberlite IRP 64M (Rohm & Haas), BIO-REX 70 (BIO-RAD Lab.), Amberlite IR118 (Rohm & Haas), Amberlite IRP 69 (Rohm & Haas), Amberlite IRP 69M(Rohm & Haas), BIO-REX 40 (BIO-RAD Lab.), Amberlite IR 120 (Rohm &Haas), Dowex 50 (Dow Chemical), Dowex 50W (Dow Chemical), Duolite C 25(Chemical Process Co.), Lewatit S 100 (Farbenfabriken Bayer), Ionac C240 (Ionac Chem.), Wofatit KP S 200 (I.G. Farben Wolfen), Amberlyst 15(Rohm & Haas), Duolite C-3 (Chemical Process), Duolite C-10 (ChemicalProcess), Lewatit KS (Farbenfabriken Bayer), Zerolit 215 (The PermutitCo.), Duolite ES-62 (Chemical Process), BIO-REX 63 (BIO-RAD Lab.),Duolite ES-63 (Chemical Process), Duolite ES-65 (Chemical Process),Ohelex 100 (BIO-RAD Lab.), Dow Chelating Resin A-1 (Dow ChemicalCompany), Purolite C115HMR (Purolite International Ltd.), CM SephadexC-25 (Pharmacia Fine Chemicals), SE Sephadex C-25 (Pharmacia FineChemicals), Viscarin GP-109NF Lambda-carrageenan FMC Biopolymer or anyother anionic polyelectrolyte.

In one another embodiment, the nicotine compound is in the form of aninclusion complex with a cyclodextrin, which may include cyclodextrincomplexation, such as complexation of the active pharmaceuticallycompound with cyclodextrin where preferably the cyclodextrin used ischosen among α-, β- and γ-cyclodextrin, the hydroxypropyl derivatives ofα-, β- and γ-cyclodextrin, sulfoalkylether cyclodextrins such assulfobutylether β-cyclodextrin, alkylated cyclodextrins such as therandomly methylated β-cyclodextrin, and various branched cyclodextrinssuch as glucosyl- and maltosyl-β-cyclodextrin.

In one embodiment, the nicotine compound is dosed in the lozenge productto provide the person with a dose to achieve an effect, e.g., to providea sense of smoking satisfaction without smoking and/or to reduce of theurge to smoke or use tobacco. This amount may, of course, vary fromperson to person.

In one embodiment, lozenge product includes the nicotine compound in anamount of from about 0.05 to about 12 mg calculated as the free baseform of nicotine per lozenge product, such as from about 0.2-6 mg, suchas from about 0.5-5 mg. This may in different embodiments include 0.05,0.5, 1, 1.5, 2, 3, 4, 4.5, 5, 6, 7, 8, 9, 10, or 12 mg calculated as thefree base form of nicotine per lozenge product.

Buffering Agent

In one embodiment, the lozenge/powder blend/coating contains bothnicotine and a buffering agent. In one embodiment, the lozenge isbuffered such that upon administration of the lozenge, the pH of thesaliva is transiently increased from about 0.2 to about 4 pH units,preferably from about 0.4 to about 2 pH units. The buffering is designedso as to achieve a transient buffering of the saliva of a subject duringuse of the lozenge product. As the change is transient, the pH willreturn to its normal value after a certain period of time.

Examples of buffering agents include, but are not limited to, carbonatesincluding carbonate, bicarbonate or sesquicarbonate, glycinate,phosphate, glycerophosphate or citrate of an alkali metal, such aspotassium or sodium, or ammonium such as trisodium or tripotassiumcitrate, trisodium phosphate, disodium hydrogen phosphate, tripotassiumphosphate, dipotassium hydrogen phosphate, calcium hydroxide, sodiumglycinate, and trometamol (TRIS). Alkali metal carbonates, glycinatesand phosphates are preferred buffering agents.

The one or more buffering agents may to some extent be microencapsulatedor otherwise coated as granules with polymers and/or lipids being lesssoluble in saliva than is the one or more buffering agents. Suchmicroencapsulation controls the dissolution rate whereby is extended thetime frame of the buffering effect.

In order to increase the buffering capacity still further withoutcorrespondingly increasing the pH, one may in specific embodiments use asecond or auxiliary buffering agent to the first buffering agent, suchas e.g., sodium or potassium bicarbonate buffers. The second orauxiliary buffering agent may be selected from the group consisting ofalkali metal bicarbonates that are preferred for this purpose. Thus,further embodiments of the invention may include a mixture of an alkalimetal carbonate or phosphate and alkali metal bicarbonate.

The amount of the buffering agent or agents in the lozenge compositionis preferably sufficient in the specific embodiments to raise the pH ofthe saliva to above 7, as specified above, to transiently maintain thepH of the saliva in the oral cavity above 7, e.g., pH 7-10.

The nicotine may be administered in different forms, e.g., in differentcomplexes or salts. The amount of buffer required to achieve such anincrease in pH of the different administered nicotine form is readilycalculated by the skilled man in the art. The extent and duration of theincrease in pH is dependent on type and amount of the buffering agent(s)used as well as where the buffer is distributed in the chewing gumproduct.

Pharmaceutically Active Agent

The powder blend/lozenge shape/lozenge product of the present inventionmay includes at least one pharmaceutically active agent (other than orin addition to a nicotine compound). What is meant by a“pharmaceutically active agent” is an agent (e.g., a compound) that ispermitted or approved by the U.S. Food and Drug Administration, EuropeanMedicines Agency, or any successor entity thereof, for the oraltreatment of a condition or disease. Suitable pharmaceutically activeagents include, but are not limited to, analgesics, anti-inflammatoryagents, antipyretics, antihistamines, antibiotics (e.g., antibacterial,antiviral, and antifungal agents), antidepressants, antidiabetic agents,antispasmodics, appetite suppressants, bronchodilators, cardiovasculartreating agents (e.g., statins), central nervous system treating agents,cough suppressants, decongestants, diuretics, expectorants,gastrointestinal treating agents, anesthetics, mucolytics, musclerelaxants, osteoporosis treating agents, stimulants, and sedatives.

Examples of suitable gastrointestinal treating agents include, but arenot limited to: antacids such as aluminum-containing pharmaceuticallyactive agents (e.g., aluminum carbonate, aluminum hydroxide,dihydroxyaluminum sodium carbonate, and aluminum phosphate),bicarbonate-containing pharmaceutically active agents,bismuth-containing pharmaceutically active agents (e.g., bismuthaluminate, bismuth carbonate, bismuth subcarbonate, bismuth subgallate,and bismuth subnitrate), calcium-containing pharmaceutically activeagents (e.g., calcium carbonate), glycine, magnesium-containingpharmaceutically active agents (e.g., magaldrate, magnesiumaluminosilicates, magnesium carbonate, magnesium glycinate, magnesiumhydroxide, magnesium oxide, and magnesium trisilicate),phosphate-containing pharmaceutically active agents (e.g., aluminumphosphate and calcium phosphate), potassium-containing pharmaceuticallyactive agents (e.g., potassium bicarbonate), sodium-containingpharmaceutically active agents (e.g., sodium bicarbonate), andsilicates; laxatives such as stool softeners (e.g., docusate) andstimulant laxatives (e.g., bisacodyl); H2 receptor antagonists, such asfamotidine, ranitidine, cimetadine, and nizatidine; proton pumpinhibitors such as omeprazole, dextansoprazole, esomeprazole,pantoprazole, rabeprazole, and lansoprazole; gastrointestinalcytoprotectives, such as sucraflate and misoprostol; gastrointestinalprokinetics such as prucalopride; antibiotics for H. pylori, such asclarithromycin, amoxicillin, tetracycline, and metronidazole;antidiarrheals, such as bismuth subsalicylate, kaolin, diphenoxylate,and loperamide; glycopyrrolate; analgesics, such as mesalamine;antiemetics such as ondansetron, cyclizine, diphenyhydroamine,dimenhydrinate, meclizine, promethazine, and hydroxyzine; probioticbacteria including but not limited to lactobacilli; lactase;racecadotril; and antiflatulents such as polydimethylsiloxanes (e.g.,dimethicone and simethicone, including those disclosed in U.S. Pat. Nos.4,906,478, 5,275,822, and 6,103,260); isomers thereof; andpharmaceutically acceptable salts and prodrugs (e.g., esters) thereof.

Examples of suitable analgesics, anti-inflammatories, and antipyreticsinclude, but are not limited to, non-steroidal anti-inflammatory drugs(NSAIDs) such as propionic acid derivatives (e.g., ibuprofen, naproxen,ketoprofen, flurbiprofen, fenbufen, fenoprofen, indoprofen, ketoprofen,fluprofen, pirprofen, carprofen, oxaprozin, pranoprofen, and suprofen)and COX inhibitors such as celecoxib; acetaminophen; acetyl salicylicacid; acetic acid derivatives such as indomethacin, diclofenac,sulindac, and tolmetin; fenamic acid derivatives such as mefanamic acid,meclofenamic acid, and flufenamic acid; biphenylcarbodylic acidderivatives such as diflunisal and flufenisal; and oxicams such aspiroxicam, sudoxicam, isoxicam, and meloxicam; isomers thereof; andpharmaceutically acceptable salts and prodrugs thereof.

Examples of antihistamines and decongestants, include, but are notlimited to, bromopheniramine, chlorocyclizine, dexbrompheniramine,bromohexane, phenindamine, pheniramine, pyrilamine, thonzylamine,pripolidine, ephedrine, phenylephrine, pseudoephedrine,phenylpropanolamine, chlorpheniramine, dextromethorphan,diphenhydramine, doxylamine, astemizole, terfenadine, fexofenadine,naphazoline, oxymetazoline, montelukast, propylhexadrine, triprolidine,clemastine, acrivastine, promethazine, oxomemazine, mequitazine,buclizine, bromhexine, ketotifen, terfenadine, ebastine, oxalamide,xylometazoline, loratadine, desloratadine, and cetirizine; isomersthereof; and pharmaceutically acceptable salts and esters thereof.

Examples of cough suppressants and expectorants include, but are notlimited to, diphenhydramine, dextromethorphan, noscapine, chlophedianol,menthol, benzonatate, ethylmorphine, codeine, acetylcysteine,carbocisteine, ambroxol, belladonna alkaloids, sobrenol, guaiacol, andguaifenesin; isomers thereof; and pharmaceutically acceptable salts andprodrugs thereof.

Examples of muscle relaxants include, but are not limited to,cyclobenzaprine and chlorzoxazone metaxalone, orphenadrine, andmethocarbamol; isomers thereof; and pharmaceutically acceptable saltsand prodrugs thereof.

Examples of stimulants include, but are not limited to, caffeine.

Examples of sedatives include, but are not limited to sleep aids such asantihistamines (e.g., diphenhydramine), eszopiclone, and zolpidem, andpharmaceutically acceptable salts and prodrugs thereof.

Examples of appetite suppressants include, but are not limited to,phenylpropanolamine, phentermine, and diethylcathinone, andpharmaceutically acceptable salts and prodrugs thereof.

Examples of anesthetics (e.g., for the treatment of sore throat)include, but are not limited to dyclonine, benzocaine, and pectin andpharmaceutically acceptable salts and prodrugs thereof.

Examples of suitable statins include but are not limited to atorvastin,rosuvastatin, fluvastatin, lovastatin, simvastatin, atorvastatin,pravastatin and pharmaceutically acceptable salts and prodrugs thereof.

In one embodiment, the powder blend includes phenylephrine,dextromethorphan, pseudoephedrine, chlorpheniramine, methocarbomal,chlophedianol, ascorbic acid, menthol, pectin, dyclonine, or benzocaine,or pharmaceutically acceptable salts thereof.

As discussed above, the pharmaceutically active agents of the presentinvention may also be present in the form of pharmaceutically acceptablesalts, such as acidic/anionic or basic/cationic salts. Pharmaceuticallyacceptable acidic/anionic salts include, and are not limited to acetate,benzenesulfonate, benzoate, bicarbonate, bitartrate, bromide, calciumedetate, camsylate, carbonate, chloride, citrate, dihydrochloride,edetate, edisylate, estolate, esylate, fumarate, glyceptate, gluconate,glutamate, glycollylarsanilate, hexylresorcinate, hydrabamine,hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isethionate,lactate, lactobionate, malate, maleate, mandelate, mesylate,methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate,pamoate, pantothenate, phosphate/diphosphate, polygalacturonate,salicylate, stearate, subacetate, succinate, sulfate, tannate, tartrate,teoclate, tosylate and triethiodide. Pharmaceutically acceptablebasic/cationic salts include, and are not limited to aluminum,benzathine, calcium, chloroprocaine, choline, diethanolamine,ethylenediamine, lithium, magnesium, meglumine, potassium, procaine,sodium and zinc.

As discussed above, the pharmaceutically active agents of the presentinvention may also be present in the form of prodrugs of thepharmaceutically active agents. In general, such prodrugs will befunctional derivatives of the pharmaceutically active agent, which arereadily convertible in vivo into the required pharmaceutically activeagent. Conventional procedures for the selection and preparation ofsuitable prodrug derivatives are described, for example, in “Design ofProdrugs”, ed. H. Bundgaard, Elsevier, 1985. In addition to salts, theinvention provides the esters, amides, and other protected orderivatized forms of the described compounds.

Where the pharmaceutically active agents according to this inventionhave at least one chiral center, they may accordingly exist asenantiomers. Where the pharmaceutically active agents possess two ormore chiral centers, they may additionally exist as diastereomers. It isto be understood that all such isomers and mixtures thereof areencompassed within the scope of the present invention. Furthermore, someof the crystalline forms for the pharmaceutically active agents mayexist as polymorphs and as such are intended to be included in thepresent invention. In addition, some of the pharmaceutically activeagents may form solvates with water (e.g., hydrates) or common organicsolvents, and such solvates are also intended to be encompassed withinthe scope of this invention.

In one embodiment, the pharmaceutically active agent or agents arepresent in the lozenge product in a therapeutically effective amount,which is an amount that produces the desired therapeutic response uponoral administration and can be readily determined by one skilled in theart. In determining such amounts, the particular pharmaceutically activeagent being administered, the bioavailability characteristics of thepharmaceutically active agent, the dose regime, the age and weight ofthe patient, and other factors must be considered, as known in the art.

The pharmaceutically active agent may be present in various forms. Forexample, the pharmaceutically active agent may be dispersed at themolecular level, e.g. melted, within the lozenge product, or may be inthe form of particles, which in turn may be coated or uncoated. If thepharmaceutically active agent is in form of particles, the particles(whether coated or uncoated) typically have an average particle size offrom about 1 to about 2000 microns. In one embodiment, such particlesare crystals having an average particle size of from about 1 to about300 microns. In another embodiment, the particles are granules orpellets having an average particle size of from about 50 to about 2000microns, such as from about 50 to about 1000 microns, such as from about100 to about 800 microns.

The pharmaceutically active agent may be present in pure crystal form orin a granulated form prior to the addition of the taste masking coating.Granulation techniques may be used to improve the flow characteristicsor particle size of the pharmaceutically active agents to make it moresuitable for compaction or subsequent coating. Suitable binders formaking the granulation include but are not limited to starch,polyvinylpyrrolidone, polymethacrylates, hydroxypropylmethylcellulose,and hydroxypropylcellulose. The particles including pharmaceuticallyactive agent(s) may be made by cogranulating the pharmaceutically activeagent(s) with suitable substrate particles via any of the granulationmethods known in the art. Examples of such granulation method include,but are not limited to, high sheer wet granulation and fluid bedgranulation such as rotary fluid bed granulation.

If the pharmaceutically active agent has an objectionable taste, thepharmaceutically active agent may be coated with a taste maskingcoating, as known in the art. Examples of suitable taste maskingcoatings are described in U.S. Pat. No. 4,851,226, U.S. Pat. No.5,075,114, and U.S. Pat. No. 5,489,436. Commercially available tastemasked pharmaceutically active agents may also be employed. For example,acetaminophen particles, which are encapsulated with ethylcellulose orother polymers by a coacervation process, may be used in the presentinvention. Coacervation-encapsulated acetaminophen may be purchasedcommercially from Eurand America, Inc. (Vandalia, Ohio) or from CircaInc. (Dayton, Ohio).

In one embodiment one or more pharmaceutically active agents or aportion of the pharmaceutically active agent may be bound to an ionexchange resin for the purposes of taste-masking the pharmaceuticallyactive agent or delivering the active in a modified release manner.

The susceptibility to energy of the pharmaceutically active agent (e.g.,to melt or degrade) can have an impact on the type of energy and/ortemperature used during the heating step as well as the type of theamorphous carbohydrate polymer used.

In one embodiment, the processing of the lozenge product is free of awet or hot melt granulation step. In this embodiment, the materials aredirectly blended prior to the addition of heat. In one embodiment, thematerials are directly blended and compressed prior to the addition ofheat.

Manufacture of Lozenge Shape

In one embodiment, the powder blend is fed into the die of an apparatusthat applies pressure to form the lozenge shape (e.g., by lightcompaction such as tamping). Any suitable compacting apparatus may beused, including, but not limited to, a conventional unitary or rotarytablet press. In one embodiment, the lozenge shape may be formed bycompaction using a rotary tablet press (e.g., such as those commerciallyavailable from Fette America Inc., Rockaway, N.J. or Manesty MachinesLTD, Liverpool, UK). In one embodiment, the lozenge shape is heatedafter it is removed from the tablet press. In another embodiment, thelozenge shape is heated within the tablet press.

In most thermodynamic processes or machines, the heat source and theheat sink are two distinct machines or steps requiring material to betransferred from one apparatus to the other. In the manufacture of thelozenges of the present invention, the energy must be added to thelozenge to achieve the binding effect and then must be removed from theproduct to solidify and strengthen it for its final handling packagingand use. One of the unique and unanticipated attributes of oneembodiment of the manufacturing process of the present invention is thatheat source and heat sink are part of the same apparatus. In oneembodiment, heat is added to the forming tools to achieve propersintering at the surface as well as at the center of the lozenge.

To exploit this unique thermal effect, powder blends can also be chosenfor their thermal properties and thermal conductivity and specific heatsuch that the powder blend particles themselves become heat sinks. Thedesirable result of this is that the total process time can be just afew seconds and that the lozenge does not need to be transferred fromthe die platen during the critical tamping and heating process. The dieplaten can function then as a material handling apparatus as well as athermal forming tool.

In one embodiment, the compaction step (e.g., tamping) which occursprior to the addition of the RF energy utilizes a compaction force whichis less than the force required to compress a chewable or swallowabletablet. In one embodiment, the compaction force is less than about 1000pounds per square inch (e.g., less than about 500 pounds per squareinch, such as less than 200 pounds per square inch, such as less than 50pounds per square inch). In one embodiment, the energy is applied whilethe powder blend is under such force.

In one embodiment, the compaction step occurs in an indexed manner,where one set of lozenges are compacted simultaneously, before rotatingto another indexing station. In one embodiment, the compaction stepoccurs at a single indexing station and the application of RF energyoccurs at a separate indexing station. In another embodiment, a thirdindexing station is present wherein the ejection of the lozenge ormultiple lozenges occurs, wherein the lower forming tool is raised upthrough and up to the surface of the die. In another embodiment thecompaction step is performed through the addition of air pressure orhydraulic cylinder to the top of the upper forming tools. In oneembodiment multiple lozenges are ejected simultaneously and separatedfrom the surface of the indexing station and removed via a take-off bar.

In another embodiment, the lozenge shape may be prepared by thecompaction methods and apparatus described in United States PatentApplication Publication No. 20040156902. Specifically, the lozenge shapemay be made using a rotary compression module including a fill zone,insertion zone, compression zone, ejection zone, and purge zone in asingle apparatus having a double row die construction. The dies of thecompression module may then be filled using the assistance of a vacuum,with filters located in or near each die. The purge zone of thecompression module includes an optional powder blend recovery system torecover excess powder blend from the filters and return the powder blendto the dies. In one embodiment the RF energy source is projected throughthe die table of a rotary press into the appropriate electrode withinthe forming tool or the forming cavity. In one embodiment the die tableis constructed of non-conductive material.

In one embodiment, the lozenge shape is prepared by the compactionmethods and apparatus described in issued U.S. Pat. No. 6,767,200.Specifically, the lozenge shape is made using a rotary compressionmodule including a fill zone, compression zone, and ejection zone in asingle apparatus having a double row die construction as shown in FIG. 6therein. The dies of the compression module are preferably filled usingthe assistance of a vacuum, with filters located in or near each die.

The lozenge shape may have one of a variety of different shapes. Forexample, the lozenge shape may be shaped as a polyhedron, such as acube, pyramid, prism, or the like; or may have the geometry of a spacefigure with some non-flat faces, such as a cone, truncated cone,triangle, cylinder, sphere, torus, or the like. In certain embodiments,a lozenge shape has one or more major faces. For example, the lozengeshape surface typically has opposing upper and lower faces formed bycontact with the upper and lower forming tool faces (e.g., die punches)in the compaction machine. In such embodiments, the lozenge shapesurface typically further includes a “belly-band” located between theupper and lower faces, and formed by contact with the die walls in thecompaction machine. A lozenge shape/lozenge may also be a multilayer.Applicants have found that sharp edges in the tooling used to make thelozenges can cause arcing, and thus more rounded edges may be needed.

In one embodiment, the method of producing the lozenge shape issubstantially free of the use of solvents. In this embodiment, thepowder blend is substantially free of solvents, and the manufacturingprocess (e.g., filling process into the die) is also substantially freeof solvents. Solvents may include, but are not limited to, water,organic solvents such as but not limited to alcohols, chlorinatedsolvents, hexanes, or acetone; or gaseous solvents such as but notlimited to nitrogen, carbon dioxide or supercritical fluids.

In one embodiment a vibratory step is utilized (e.g., added afterfilling of the powder blend but prior to the heating or fusing step, inorder to remove air from the powder blend). In one embodiment avibration with the frequency from about 1 Hz to about 50 KHz is addedwith amplitude from 1 micron to 5 mm peak-to-peak to allow for theflowable powder blend to settle into the cavity of a the die platen(“forming cavity”).

In one embodiment, as shown in FIGS. 1A-1F, a metered volume of powderblend 4 is filled into a Teflon® (or similar electrical and RF energyinsulative material such as ceramic or UHMW plastic) die platen 2. Dieplaten 2 has forming cavity 5 with inner wall 6, upper opening 7 on theupper surface of die platen 2 (which allows powder blend 4 and upperforming tool 1 to move into the forming cavity 5), and lower opening 8on the opposite surface of die platen 2 (which allows powder blend 4 andlower forming tool 3 to move into the forming cavity 5). Powder blend 4may be either gravity fed or mechanically fed from a feeder (not shown).A metallic, electrically conductive lower forming tool 3 is insertedinto the die platen to retain the powder blend 4, within die platen 2. Asimilar metallic, electrically conductive upper forming tool 1 ispositioned above the die platen 2 as shown in FIG. 1B. The forming tools1 and 3, die platen 2, and powder blend 4 are then moved to a compactionand RF heating station as shown in FIG. 1C to form lozenge shape 4 a.

This heating station is comprised of an RF generator 7 which producesthe necessary high voltage, high frequency energy. The generator 7 iselectrically connected to movable upper RF electrode plate 8 and movablelower RF electrode plate 6. As shown in FIG. 1C, at this position, thepowder blend 4 is compacted between an upper forming tool 1 and a lowerforming tool 3 by pressure exerted by upper RF electrode plate 8 andlower electrode plate 6 to form lozenge shape 4 a. Lozenge shape 4 a isthen exposed to RF energy from RF generator 7, which heats the amorphouscarbohydrate polymer within lozenge shape 4 a. After the RF energy isswitched off, lozenge shape 4 a cools to form the lozenge 4 b. In oneembodiment, as shown in FIG. 1D, lozenge 4 b is pushed by upper formingtool 1 from the die platen 2 into blister 8, which is used to packagelozenge 4 b. In an alternative embodiment, as shown in FIG. 1E, lozenge4 b is pushed from the die platen 2 by the lower forming tool 3 andguided to an ejection chute by a stationary “take-off” bar (not shown).FIG. 1F shows a 3 dimensional representation of the forming tools 1 and4, die platen 2, and lozenge 4 b.

In FIGS. 2A-2H, an alternate embodiment of the invention is shown wherea multilayer lozenge is produced. First, powder blend 10 is filled intodie platen 2 as shown in FIG. 2A. Powder blend 10 is tamped or moveddown into die platen 2 by upper forming tool 1 as shown in FIG. 2B toform lozenge shape 10 a. Then, powder blend 11 is then filled on top oflozenge shape 10 a. The forming tools 1 and 3, die platen 2, lozengeshape 10 a and powder blend 11 are then moved to the compaction and RFheating station as shown in FIG. 2E. RF heating is accomplished asdescribed above in FIG. 1C to produce multilayer lozenge 12 as shown inFIGS. 2F and 2G. While a bi-layer lozenge is shown in the drawing,additional multiple layers can be produced by adding additional powderblends to die platen 2.

FIGS. 3A-3G show another embodiment of the invention where preformedinserts 30 and 31 are inserted into lozenge shape 20 a as shown in FIGS.3A-3D. Forming tools 1 and 3, die platen 2, lozenge shape 20, andpreformed inserts 30 and 31 are then moved to the compaction and RFheating station as shown in FIG. 3E. RF heating is accomplished asdescribed above in FIG. 1C to produce a multi-component lozenge 40 shownin FIGS. 2F and 2G.

FIGS. 4A and 4B show two views of a rotary indexing machine 195 which isdesigned to create large quantities of lozenges. This embodiment of theinvention is comprised of an indexing table 170 having four sets of dieplatens 175 each having sixteen cavities, powder feeder 100, RFgenerator 150, a machine frame 140, moving RF electrode assemblies 120and 130, lower forming tool assembly 110, upper forming tool assembly210, lozenge ejection station 160, indexer drive system 180, blisterpackage web 190, and blister lid material roll 191.

FIG. 5A is a top view of the apparatus in the dwell position. FIG. 5B isa top view of the apparatus as the indexing table 170 rotates betweenstations in direction “A”. FIG. 6A depicts a section view through thelower forming tool assembly 110 in a start position of the manufacturingcycle. The lower forming tools 111, which are made of an electricallyconductive metallic material such as brass or stainless steel, areretained in retainer plate 112 (e.g., made of aluminum or steel). Heatedblock 117 is attached to the retainer plate 112 and contains fluidpassages 117 b. Heated (or optionally cooling) fluid is circulatedthrough the heated block 117 by connections to flexible hoses 119 a and119 b which form a supply and return circuit. Heating can also beaccomplished by electric cartridge heaters or other suitable means (notshown). Attached to the retainer plate are cam-follower 114 and linearbearing 113. A guide shaft 116 is fixed to indexing table 170. Theretainer plate and forming tools 111 and are moveable up or downaccording to the profile of barrel cam 115 which cam follower 114 rollsupon. Also shown is die platen 171, which is made of electrical and RFenergy insulative material such as Teflon, UHMW, or ceramic. This isnecessary to prevent a short circuit when the electrically conductiveforming tools are positioned in the RF electric field in subsequentsteps. The forming cavity 171 a is shown empty at this stage of theprocess.

FIG. 6B depicts a section through the powder feeder station 100 of theapparatus. In this station powdered powder blend 101 is gravity fed intodie platen 171. Movable cam segment 118 is adjusted up or down indirection “B” to vary the volume of the forming cavity 171 a by changingthe amount that the lower forming tools 111 penetrate into the dieplaten 171. This adjustable volume feature enables the precise dose ofpowdered powder blend to be selected for a desired lozenge weight. Whenthe machine indexes out of the powder feeder station, the rim of feeder102 scrapes against the die platen 171 to create a level powder surfacerelative to the surface of the die platen 171.

FIG. 7 is a section view through the RF station of the apparatus. The RFgenerator 150 is depicted symbolically here. In one embodiment, theconfiguration of the RF generator 150 is a free running oscillatorsystem. It is typically composed of a power vacuum tube (such as atriode), a DC voltage source between 1000 and 8000 volts connectedacross the cathode and plate (anode). A tank circuit is used to impose asinusoidal signal upon the control grid and electrodes thereby producingthe necessary frequency (typically 13.56 MHZ or 27.12 MHZ) and highvoltage field. An example of such RF generator 150 is the COSMOS ModelC10X16G4 (Cosmos Electronic Machine Corporation, Farmingdale, N.Y.). Inanother embodiment, RF energy can be provided by a 50 Ohm systemcomposed of a waveform generator which feeds a radio frequency signal topower amplifiers which are coupled to the electrodes and the load by animpedance matching network.

In FIG. 7, a lower movable RF electrode 121 is shown, movable indirection “D”. It is represented in its down position. The linearmovement is generated by linear actuators which are typically devisessuch as air cylinders or servo motors. Two air cylinders are depicted inFIG. 7. Air cylinder bodies 141 and 142 apply pressure to guide rods 144and 143. Moving platens 132 and 122 are connected to the guide rods andprovide an electrically isolated mounting for electrode plates 131 and121. RF generator 150 connects to the electrode plates 131 and 121through wires 185 and 184. A movable upper RF electrode assembly 130,movable in direction “C”, is shown in its up position. Upper formingtools 133, retainer plate 134, and heated block 135 are all attached tothe movable RF electrode plate 131 and, consequently, move up and downwith it. Powder blend 101 is within die platen 171.

FIG. 8 is a section through the same RF station but shows the RFelectrodes 131 and 121 pressing against the respective forming toolassemblies 133 and 111 to both compact and apply RF energy to powderblend 101 creating lozenge 101 a. After application of the RF energy isstopped, the moveable RF electrode plates retract, and the indexingplate 170, die platen 171, and lower forming tool assembly 110 areindexed to the next station.

FIG. 9 is a section view through the lozenge ejection station 160.Ejector pins 161 are attached to movable plate 162 (movable in the “E”direction), which is actuated by actuator assembly 163 (for example,this can be a linear servo motor or air cylinder or other suitableactuator). Actuator rod 166 connects to the movable plate 162. Linearbearing 164 and guide rod 165 provide rigidity and support for theactuator plate 162 and prevent destructive side loads created by theejection force from acting upon actuator 163. A blister package 190 isshown below die platen 171.

FIG. 10 is a section through the same assembly after the ejector pins161 have pushed finished lozenges 101 a through the die platen 171. Thisdirect placement of lozenge into blister helps prevent breakage thatcould occur while using typical means such as feeders or by dumpinglozenges into transport drums.

In one embodiment, a lubricant is added to forming cavity prior to theaddition of the flowable powder blend. This lubricant may be a liquid orsolid. Suitable lubricants include but are not limited to solidlubricants such as magnesium stearate, starch, calcium stearate,aluminum stearate and stearic acid; or liquid lubricants such as but notlimited to simethicone, lecithin, vegetable oil, olive oil, or mineraloil. In certain embodiments, the lubricant is added at a percentage byweight of the lozenge of less than 5 percent, e.g. less than 2 percent,e.g. less than 0.5 percent. In certain embodiments, the presence of ahydrophobic lubricant can disadvantageously compromise thedisintegration or dissolution properties of a lozenge. In one embodimentthe lozenge is substantially free of a hydrophobic lubricant.Hydrophobic lubricants include magnesium stearate, calcium stearate andaluminum stearate.

Radiofrequency Heating of Lozenge Shape to Form Lozenge

Radiofrequency heating generally refers to heating with electromagneticfield at frequencies from about 1 MHz to about 100 MHz. In oneembodiment of the present invention, the RF-energy is within the rangeof frequencies from about 1 MHz to about 100 MHz (e.g., from about 5 MHzto 50 MHz, such as from about 10 MHz to about 30 MHz). The RF-energy isused to heat the amorphous carbohydrate polymer. The degree ofcompaction, the type and amount of amorphous carbohydrate polymer, andthe amount of RF energy used can determine the hardness and/or type oflozenge.

RF energy generators are well known in the art. Examples of suitable RFgenerators include, but are not limited to, COSMOS Model C10X16G4(Cosmos Electronic Machine Corporation, Farmingdale, N.Y.).

In one embodiment, the upper and lower forming tools serve as theelectrodes (e.g., they are operably associated with the RF energysource) through which the RF energy is delivered to the lozenge shape.In one embodiment, there is direct contact between at least one RFelectrode (e.g., forming tool) and the lozenge shape. In anotherembodiment, there is no contact between any of the RF electrode (e.g.,forming tools) and the lozenge shape. In one embodiment, the RFelectrodes are in direct contact with the surface of the lozenge shapewhen the RF energy is added. In another embodiment, the RF electrodesare not in contact (e.g., from about 1 mm to about 1 cm from the surfaceof the lozenge shape) during the addition of the RF energy.

In one embodiment, the RF energy is delivered while the lozenge shape isbeing formed. In one embodiment, the RF energy is delivered once thelozenge shape is formed. In one embodiment, the RF energy is deliveredafter the lozenge shape has been removed from the die.

In one embodiment, the RF energy is applied for a sufficient time tosoften and melt substantially all (e.g., at least 90%, such as at least95%, such as all) of the amorphous carbohydrate polymer within thelozenge shape. In one embodiment, the RF energy is applied for asufficient time to soften and melt only a portion (e.g., less than 75%,such as less than 50%, such as less than 25%) of the amorphouscarbohydrate polymer within the lozenge shape, for example only on aportion of the lozenge shape, such as the outside of the lozenge shape.

In alternate embodiments of the invention, the forming tools can beconstructed to achieve localized heating effects and can also beconfigured to shape the electric field that is developed across thetools. FIG. 11A shows one such configuration. An RF generator 200 isconnected to RF electrode plates 201 and 202. Forming tools 205 and 204are constructed of an electrically conductive material and they have anattachment 207 and 208 which are made of electrical and RF energyinsulative material such as ceramic, Teflon®, polyethylene, or highdensity polyethylene. Die platen 203 is also constructed of electricaland RF energy insulative material. This configuration creates greaterdistance between the conductive forming tools to weaken the electricfield which is beneficial for producing thin lozenges without the riskof an electric arc forming which would damage the product and tooling.FIG. 11B depicts a similar configuration but with forming tools 210 and211 that, respectively, have a recess containing insert 213 and 212which are made of electrical and RF energy insulative material. Thisgeometry will produce a lozenge with lesser heating in the area wherethe inserts 213 and 212 are located since the electric field is weakerdue to the greater distance between the conductive portions of 211 and210. FIG. 11C is similar to FIG. 11B only the geometry is reversed sothe lozenge formed by this configuration will have a greater heatingeffect at the center since the inserts 216 and 217 are at the peripheryof respective forming tools 214 and 215. FIG. 11D depicts anotherembodiment whereby the die platen is constructed of an electricallyconductive component 221 and electrically insulating component 222,which is made of electrical and RF energy insulative material. Formingtools 219 and 218 are electrically conductive, but forming tool 218further contains second electrically insulating component 220 around thesurface of upper forming tool 218 which contact lozenge shape 206. Thisconfiguration creates an electric field and associated zones of heatingthat is preferential to the conductive portions of the die platen.

FIG. 12A is similar to FIG. 11D except the die platen 233 in thisembodiment is constructed entirely of electrically conductive material.FIGS. 12B and 12C depict two embodiments where the die platen comprisesa respective center portion 245 and 254 that are electrically conductiveand respective outer portions 244/246 and 252/253 is are made ofelectrical and RF energy insulative material. FIG. 12B further includesinsulating component 220 around the surface of lower forming tool 219.FIG. 12D is a further embodiment where the forming tools 263 and 262 aremade of electrical and RF energy insulative material. The die platenportions 264 and 265 are made of electrical and RF energy insulativematerial, but there are two respective electrically conductive portions267 and 266 which are attached to the RF generator circuit 200. In thisconfiguration, the electric field is applied in the horizontal directionacross the lozenge shape 206.

As described above, the distance between conductive portions of theforming tool has a strong effect on field strength and heating effect.To create a lozenge with uniform heating and texture, a forming toolthat is constructed with equidistant spacing is desirable. FIGS. 13A and13B depict such a configuration. In this embodiment, a wave-shapedforming tools 270 and 273 are shown to create a lozenge 272 within dieplaten 271 with a unique appearance. The profiles of the forming toolsurfaces are equidistant as shown by dimension “X”.

FIG. 14 is an embodiment wherein a non-uniform heating is used tomanufacture lozenge 282. In this embodiment, a lozenge with hard andsoft zones is created. The forming tools 280 and 281 are made withprotrusions at the surface that create high field strength (resulting ingreater heating) where they are closest together (shown by the dimension“Z”) and weaker field strength (resulting in lesser heating) where theyare further apart (shown by the dimension “Y”).

In one embodiment, to help reduce sticking, the lozenge is cooled withinthe forming cavity to cool and/or solidify the amorphous carbohydratepolymer. The cooling can be passive cooling (e.g., at room temperature)or active cooling (e.g., coolant recirculation cooling). When coolantrecirculation cooling is used, the coolant can optionally circulatethrough channels inside the forming tools (e.g., punches or punchplaten) and/or die or die platen (e.g., as discussed above in FIGS. 6Aand 6B). In one embodiment, the process uses a die platen havingmultiple die cavities and upper and lower punch platens having multipleupper and lower punched for simultaneous forming of a plurality oflozenges wherein the platens are actively cooled.

In one embodiment, there is a single powder blend forming the lozengeshape which is then heated with the RF energy. In another embodiment,the lozenge is formed of at least two different powder blends, at leastone powder blend being RF-curable and at least one formulation being notRF-curable. When cured with RF energy, such lozenge shape develops twoor more dissimilarly cured zones. In one embodiment, the outside area ofthe lozenge shape is cured, while the middle of the lozenge shape is notcured. By adjusting the focus of the RF heating and shape of the RFelectrodes, the heat delivered to the lozenge shape can be focused tocreate customized softer or harder areas on the finished lozenge.

In one embodiment the RF energy is combined with a second source of heatincluding but not limited to infrared, induction, or convection heating.In one embodiment, the addition of the second source of heat isparticularly useful with a secondary non-RF-meltable binder present inthe powder blend.

Microwave Heating of Lozenge Shape to Form Lozenge

In one embodiment, microwave energy is used in place of radiofrequencyenergy to manufacture the lozenge. Microwave heating generally refers toheating with electromagnetic field at frequencies from about 100 MHz toabout 300 GHz. In one embodiment of the present invention, the RF-energyis within the range of frequencies from about 500 MHz to about 100 GHz(e.g., from about 1 GHz to 50 GHz, such as from about 1 GHz to about 10GHz). The microwave energy is used to heat the amorphous carbohydratepolymer. In such an embodiment, a microwave energy source and microwaveelectrodes are used in the machine used to manufacture the dosage form.

Inserts within Lozenge Shape

In one embodiment, an insert is incorporated into the lozenge shapebefore the energy is delivered. Examples include solid compressed formsor beads filled with a liquid composition.

In one embodiment, the nicotine compound and/or the pharmaceuticallyactive agent is in the form of a gel bead, which is liquid filled orsemi-solid filled. The gel bead(s) are added as a portion of the powderblend. In one embodiment, the lozenge product of this invention has theadded advantage of not requiring a strong compaction step, allowing forthe use of liquid or semisolid filled particles or beads which aredeformable since they will not rupture following the reduced pressurecompaction step. These bead walls may contain gelling substances suchas: gelatin; gellan gum; xanthan gum; agar; locust bean gum;carrageenan; polymers or polysaccharides such as but not limited tosodium alginate, calcium alginate, hypromellose, hydroxypropyl celluloseand pullulan; polyethylene oxide; and starches. The bead walls mayfurther contain a plasticizer such as glycerin, polyethylene glycol,propylene glycol, triacetin, triethyl citrate and tributyl citrate. Thepharmaceutically active agent may be dissolved, suspended or dispersedin a filler material such as but not limited to high fructose cornsyrup, sugars, glycerin, polyethylene glycol, propylene glycol, or oilssuch as but not limited to vegetable oil, olive oil, or mineral oil.

In one embodiment, the insert is substantially free of RF-absorbingingredients, in which case application of the RF energy results in nosignificant heating of the insert itself. In other embodiments, theinsert contains ingredients and are heated upon exposure to RF energyand, thus, such inserts can be used to melt/soften the amorphouscarbohydrate polymer.

Multiple Layer Lozenges

In certain embodiments, the chewing includes at least two layers, e.g.,with different types and/or concentrations of amorphous carbohydratepolymers and/or other ingredients or different concentrations ofpharmaceutically active agents. Such an embodiment is shown in FIGS.2A-2D. In one embodiment, the lozenge is a bilayer form; wherein thefirst layer is a lozenge form and the second layer is a orallydisintegrating form. In one embodiment the first layer is a lozenge formand the second layer is a lozenge form. In one embodiment the lozengeform layer is free of a material that reacts to RF heating. In oneembodiment, the lozenge form layer or the orally disintegrating formlayer is first compressed as a layer, then the powder blend is added tothe compressed lozenge or compressed orally disintegrating form layerand the entire form is energized utilizing the RF apparatus.

In one embodiment, the lozenge layer or the orally disintegrating formlayer includes at least one material that reacts to RF heating, such asa RF heatable meltable binder or a RF heatable sugar or sugar alcohol.In one embodiment the lozenge powder blend or the orally disintegratingform blend is added to the die, and the entire form is energizedutilizing the RF apparatus. In another version of this embodiment, theorder of addition of the lozenge powder or orally disintegrating formblend into the RF apparatus is reversed.

In certain embodiments, the lozenge product includes at least two layershaving different types and/or concentrations of ingredients (e.g.,colorants or pharmaceutically active agents) within the powder blend.Such embodiments may be made by sequentially adding the powder blendsthat make the respective layers, forming the powders blends into thedesires share of the lozenge product, and applying RF energy to theformed shape.

In another embodiment, the lozenge product further includes a secondlayer which is not a lozenge layer (e.g., a layer having orallydisintegrating properties). In such an embodiment, upon administrationof such a lozenge product having an additional orally disintegratinglayer, the orally disintegrating layer quickly disintegrates in themouth of the user, leaving the lozenge product to be sucked on by theuser. In one such embodiment, the orally disintegrating layer containsone pharmaceutically active agent (e.g., an analgesic, antihistamine,decongestant, cough suppressant, or expectorant) and the lozenge producteither does not contain a pharmaceutically active agent or contains adifferent pharmaceutically active agent (e.g., menthol).

Surface Treating of the Lozenge Product

In one embodiment, the surface of the lozenge shape and/or the lozengeproduct is further treated with energy (e.g., convection, infrared, orRF energy) to soften or melt the material on the surface of the lozengeproduct and then cooled or allowed to cool to further smooth thetexture, enhance the gloss of surface of the lozenge product, limit thefriability of the lozenge product, and/or provide a mark foridentification. In one embodiment, the surface of the lozenge product isfurther exposed to infrared energy wherein the majority (at least 50percent, such as least 90 percent, such as at least 99 percent) of thewavelength of such infrared energy is from about 0.5 to about 5micrometers such as from about 0.8 to about 3.5 micrometers (e.g., byuse of a wavelength filter). In one embodiment, the infrared energysource is a quartz lamp with a parabolic reflector (e.g., to intensifythe energy) and a filter to remove unwanted frequencies. Examples ofsuch infrared energy sources include the SPOT IR 4150 (commerciallyavailable from Research, Inc., Eden Prairie, Minn.).

Surface Gloss

In one embodiment, the lozenge product has a gloss of at least 250 glossunits, such as at least 300 gloss units, when tested using a Tri-CorModel 805A/806H Surface Analysis System available from TriCor SystemsInc. (Elgin, Ill.) in accordance with the procedure described in “TriCorSystems WGLOSS 3.4 Model 805A/806H Surface Analysis System ReferenceManual” (1996), which is incorporated by reference herein (hereinafter“gloss units”).

Use of Lozenge Product

In one embodiment, the lozenge product does not contain a nicotinecompound or a pharmaceutically active agent, and is used just as a candyby the user. In one embodiment, the present invention features a methodof treating an ailment, the method including orally administering theabove-described wherein the lozenge product includes an amount of thenicotine compound and/or pharmaceutically active agent effective totreat the ailment. Examples of such ailments include, but are notlimited to, pain (such as headaches, migraines, sore throat, cramps,back aches and muscle aches), fever, inflammation, upper respiratorydisorders (such as cough and congestion), infections (such as bacterialand viral infections), depression, diabetes, obesity, cardiovasculardisorders (such as high cholesterol, triglycerides, and blood pressure),gastrointestinal disorders (such as nausea, diarrhea, irritable bowelsyndrome and gas), sleep disorders, osteoporosis, and nicotine and/ortobacco dependence.

In this embodiment, the “unit dose” is typically accompanied by dosingdirections, which instruct the patient to take an amount of thepharmaceutically active agent that may be a multiple of the unit dosedepending on, e.g., the age or weight of the patient. Typically the unitdose volume will contain an amount of pharmaceutically active agent thatis therapeutically effective for the smallest patient. For example,suitable unit dose volumes may include one lozenge product.

EXAMPLES

Specific embodiments of the present invention are illustrated by way ofthe following examples. This invention is not confined to the specificlimitations set forth in these examples.

Example 1 Preparation of Placebo Lozenge Products

The lozenge products of Table 1 are prepared as follows. The sucralose,peppermint flavor and polydextrose are manually passed through a 50 meshscreen. The above mixture is placed into a plastic bottle, mixedend-over end for approximately three minutes, and then discharged. Thepowder blend is then individually dosed into an electrically insulativeTeflon die platen having a cavity that is ½ inch in diameter. 1 mm thickTeflon discs are placed between the powder blends and the metal formingtools to help prevent arcing. The powder blend is then tamped between anupper and lower metal forming tools at about 60 psi of pressure. Theforming tools, die platen and lozenge shape are then placed between theupper RF electrode and lower RF electrode powered by an RF heating unitusing a COSMOS Model C10X16G4 (Cosmos Electronic Machine Corporation,Farmingdale, N.Y.) RF generator having an output of 4 KW of power,frequency of 27 MHz, and the vacuum capacitor is set at 140. The formingtools are heated with recirculating water at a temperature of 57° C. Theupper RF electrode is brought into contact with the upper forming tooland the lower RF electrode is brought into contact with lower formingtool. The RF heating unit is energized for 5-15 seconds. The resultinglozenge product is then ejected from the die platen using the lowerforming tool

TABLE 1 Material G/Batch mg/lozenge Weight % Sucralose 0.063 5.25 0.50Peppermint Flavor¹ 0.126 10.50 1.00 Polydextrose² 12.411 1034.25 98.50TOTAL 12.600 1050.00 100.0 ¹Commercially available from Virginia Dare inBrooklyn, NY ²Commercially available from Danisco in Ardsley, NY

Example 2 Preparation of Coated Taste-Masked Dextromethorphan

Part A: Preparation of Layered Active Ingredient

An aqueous solution is prepared containing the following ingredients:Dextromethorphan Hydrobromide (20.0%); Polyvinyl Pyrrolidone (K29/32grade) (1.0%); and Purified Water (79.0%). 1.96 kg of Microcrystallinecellulose (Avicel PH 200 Grade, commercially available from FMCCorporation) is charged into a fluidized bed coating apparatus (GlattModel GPCG 5/9) fitted with a Rotor (tangential spray) Attachment. Themicrocrystalline cellulose is fluidized at an air flow at 36° C. and thedextromethorphan solution is sprayed at a rate of 80 g/minute, until themicrocrystalline cellulose contains by weight of the layered particlesapproximately 40% by weight of dextromethorphan HBr.

Part B: Preparation of Coated Active Ingredient

A coating solution is prepared containing Cellulose Acetate 398-10(commercially available from Eastman Chemical) and Eudragit E-100(commercially available from Rohm Pharma) at a level of about 12% solidsat a ratio of 80:20 Cellulose Acetate:Eudragit in acetone (totalsolution weight equal to 10.7 kg). A 3.0 kg portion of the particlesprepared in Part A are charged into the rotor fluidized bed coatingapparatus (Glatt Model GPCG 5/9). The drug-layered particles arefluidized at 36° C. and the polymer solution is sprayed on at a rate of40 g/minute until the drug particles contain approximately 20% by weightof the polymer coating.

Example 3 Preparation of Lozenge Products Containing CoatedDextromethorphan

The lozenges of Table 2 are prepared as follows. The sucralose,peppermint flavor and polydextrose are manually passed through a 50 meshscreen. The above mixture is combined with the coated dextromethorphanfrom Example 2 and placed in a plastic bottle, mixed end-over end forapproximately three minutes, and then discharged. The powder blend isthen placed into the forming cavity, tamped, and activated with RFenergy as described in Example 1 to form the lozenge and subsequentlyremoved from the die platen.

TABLE 2 Material G/Batch mg/lozenge Weight % Sucralose 0.46 5.25 0.46Coated Dextromethorphan (32%)* 7.93 90.45 7.93 Peppermint Flavor¹ 0.9210.50 0.92 Polydextrose² 90.69 1034.25 90.69 TOTAL 100.0 1140.45 100.0¹Commercially available from Virginia Dare in Brooklyn, NY ²Commerciallyavailable from Danisco in Ardsley, NY

Example 4 Preparation of Lozenge Products Containing Menthol

The lozenges of Table 3 are prepared as follows. The sucralose,peppermint flavor and polydextrose are manually passed through a 50 meshscreen. The above mixture is combined with the menthol and placed in aplastic bottle, mixed end-over end for approximately three minutes, andthen discharged. The powder blend is then placed into the formingcavity, tamped, and activated with RF energy as described in Example 1to form the lozenge and subsequently removed from the die platen.

TABLE 3 Material G/Batch mg/lozenge Weight % Sucralose 0.49 5.25 0.49Menthol 1.13 12.00 1.13 Peppermint Flavor¹ 0.99 10.50 0.99 Polydextrose²97.39 1034.25 97.39 TOTAL 100.0 1062.00 100.0 ¹Commercially availablefrom Virginia Dare in Brooklyn, NY ²Commercially available from Daniscoin Ardsley, NY

Example 5 Preparation of Lozenge Products Containing Nicotine BitartrateDihydrate

The lozenges of Table 4 are prepared as follows. The sucralose,peppermint flavor and polydextrose are manually passed through a 50 meshscreen. The above mixture is combined with the nicotine bitartratedihydrate and L-Arginine and placed in a plastic bottle, mixed end-overend for approximately three minutes, and then discharged. The powderblend is then placed into the forming cavity, tamped, and activated withRF energy as described in Example 1 to form the lozenge and subsequentlyremoved from the die platen.

TABLE 4 Material G/Batch mg/lozenge Weight % Sucralose 0.49 5.25 0.49Nicotine Bitartrate Dihydrate 0.29 3.08* 0.29 (32.55% Nicotine)L-Arginine 2.01 21.6 2.01 Peppermint Flavor¹ 0.98 10.50 0.98Polydextrose² 96.24 1034.25 96.24 TOTAL 100.0 1074.68 100.0¹Commercially available from Virginia Dare in Brooklyn, NY ²Commerciallyavailable from Danisco in Ardsley, NY *Equivalent to a 1.0 mg Dose ofNicotine

Example 6 Preparation of Lozenge Products Containing Nicotine ResinComplex

The lozenges of Table 5 are prepared as follows. The sucralose,peppermint flavor and polydextrose are manually passed through a 50 meshscreen. The above mixture is combined with the nicotine resin complexand the trometamol and placed in a plastic bottle, mixed end-over endfor approximately three minutes, and then discharged. The powder blendis then placed into the forming cavity, tamped, and activated with RFenergy as described in Example 1 to form the lozenge and subsequentlyremoved from the die platen.

TABLE 5 Material G/Batch mg/lozenge Weight % Sucralose 0.50 5.25 0.50Nicotine Resin Complex (20% 0.24 2.50* 0.24 Nicotine) Trometamol 0.717.5 0.71 Peppermint Flavor¹ 0.99 10.50 0.99 Polydextrose² 97.57 1034.2597.57 TOTAL 100.0 1060.00 100.0 ¹Commercially available from VirginiaDare in Brooklyn, NY ²Commercially available from Danisco in Ardsley, NY*Equivalent to a 0.5 mg Dose of Nicotine

Example 7 Manufacture of Bi-Layer Lozenge Product Orally DisintegratingLayer

Part A: Preparation of Powder Blend Containing Loratadine

The loratadine powder blend for an orally disintegrating layer,containing the ingredients of Table 6, is manufactured as follows:

TABLE 6 Ingredient G/Batch Mg/Layer Dextrose Monohydrate 45.18 120Loratadine 3.765 10 Polyethylene Glycol 4000 24.475 65 Maltodextrin15.062 40 Red Colorant 0.028 0.075 Simethicone DC100 5.648 15 SucraloseUSP 1.13 3 Polyethylene Oxide 1.883 5 Mint Flavor 2.824 7.5 Total 100265.58

First, the sucralose, colorant, and flavor are placed together into a500 cc sealable plastic bottle. The mixture is then blended end-over-endmanually for approximately 2 minutes. The resulting mixture, thedextrose monohydrate, loratadine, and the polyethylene oxide are thenadded to another 500 cc sealable plastic bottle and mixed end-over-endmanually for approximately 5 minutes. The resulting mixture is thenadded to a planetary bowl mixer, and the simethicone DC 100 is added andmixed for approximately 3 minutes. Lastly, the polyethylene glycol 4000and the maltodextrin is added to the mixture and mixed for approximately3 minutes.

Part B: Manufacture of Orally Disintegrating and Lozenge Bi-Layer DosageForm

A 1062 mg 265.58 mg portion of the powder blend from Example 4 is placedinto a non-conductive die platen, approximately ½ inch in diameter. Thepowder blend is then placed into the forming cavity, tamped, andactivated with RF energy as described in Example 1 (but the RF heatingunit is energized for 15 seconds). The upper forming tool is thenremoved and 265.58 mg of the blend from Example 7(a) containingloratadine is added. The forming tool is reinserted into the formingcavity and the RF heating unit is then energized for an additional 2seconds. The resulting final bilayer dosage form is then ejected fromthe die using the lower tool.

Example 8 Nicotine Lozenge Prepared using Hydrogen Starch Hydrolysate

The lozenges of Table 7 are prepared as follows. The sucralose,peppermint flavor and hydrogenated starch hydrolysate are manuallypassed through a 50 mesh screen. The above mixture is then combined withthe nicotine resin complex, and the remaining materials and placed in aplastic bottle, mixed end-over end for approximately three minutes, andthen discharged. The powder blend is then placed into the formingcavity, tamped, and activated with RF energy as described in Example 1to form the lozenge and subsequently removed from the die platen.

TABLE 7 Material G/Batch mg/lozenge Weight % Hydrogenated StarchHydrolysate¹ 190.90 954.50 94.45 Sodium Bicarbonate USP 0.50 2.50 0.25Sodium Carbonate, Anhydrous 1.00 5.00 0.50 Nicotine Resin Complex (20%2.20 11.00* 1.10 Nicotine) Acesulfame Potassium E950 Type D³ 0.40 2.000.20 Peppermint Flavor¹ 4.00 20.00 2.00 Micronized Sucralose 1.00 5.000.50 TOTAL 200.0 1060.00 100.0 ¹Commercially available as Stabilite PD30Polyglycitol (HSH), commercially available from the Corn ProductsCompany, in Westchester, IL, USA ²Commercially available from VirginiaDare in Brooklyn, NY ³Commercially available from the Nutrinova Companyin Frankfurt, Germany *Equivalent to a 2 mg dose of Nicotine

It is understood that while the invention has been described inconjunction with the detailed description thereof, that the foregoingdescription is intended to illustrate and not limit the scope of theinvention, which is defined by the scope of the appended claims. Otheraspects, advantages, and modifications are within the claims.

What is claimed is:
 1. A process for making a lozenge, said methodcomprising the steps of forming a powder blend comprising an amorphouscarbohydrate polymer into the desired shape of said lozenge in a die ofan apparatus and applying RF energy from said apparatus to said shapewithin said die for a sufficient period of time to soften or melt saidamorphous carbohydrate polymer to fuse said powder blend into saidlozenge; wherein said process comprises the steps of: (i) introducingsaid powder blend into a forming cavity within said die platen; (ii)compacting said powder blend by introducing at least one forming toolinto said die platen with sufficient force such that the shape of thelozenge is formed; (iii) applying said radiofrequency energy to saidshape within said forming cavity to form said lozenge wherein said atleast one said forming tool or said die platen emits said radiofrequencyenergy to said lozenge shape; and (iv) removing said lozenge from saidforming cavity.
 2. The process of claim 1, wherein said RF energy has afrequency of from about 1 MHz to 100 MHz.
 3. The process of claim 1,wherein said amorphous carbohydrate polymer is selected from the groupconsisting of polydextrose, fructo-oligosaccharide,galacto-oligosaccharide, malto-oligosaccharide,isolmalto-oligosaccharide, and hydrogenated starch hydrolysate.
 4. Theprocess of claim 1, wherein said powder blend comprises nicotine or asalt thereof.
 5. The process of claim 1, wherein said powder blendcomprises a pharmaceutically active agent.
 6. The process of claim 1,wherein said powder blend comprises phenylephrine, dextromethorphan,pseudoephedrine, chlorpheniramine, methocarbomal, chlophedianol,ascorbic acid, menthol, pectin, dyclonine, and benzocaine, andpharmaceutically acceptable salts thereof.
 7. The process of claim 1,wherein said powder blend comprises from about 50 to about 99.9 percent,by weight, of said amorphous carbohydrate polymer.
 8. The process ofclaim 1, wherein the lozenge has a gloss of at least 250 gloss units. 9.The process of claim 1, wherein said process further comprises adding asecond powder blend to said die wherein said second powder blend isdifferent from the first powder blend.
 10. The process of claim 1,wherein said process further comprises the step of cooling said lozengein said die prior to removing said lozenge from said die.
 11. Theprocess of claim 1, wherein said at least one said forming tool emitssaid radiofrequency energy to said shape.
 12. The process of claim 1,wherein the die platen emits said radiofrequency energy to said shape.13. The process of claim 1, wherein said powder blend is compacted usingan upper forming tool and a lower forming tool, and at least one of saidupper forming tool or lower forming tool emits said radiofrequencyenergy to said shape.
 14. The process of claim 1, wherein said processfurther comprises adding a second powder blend to said forming cavityprior to said step of applying radiofrequency energy to shape, whereinsaid second powder blend is different from said powder blend.
 15. Theprocess of claim 1, wherein the surface of said lozenge is furtherexposed to infrared energy wherein the majority of the wavelength ofsaid infrared energy from about 0.5 to about 5 micrometers.
 16. Alozenge manufactured according to the process of claim
 1. 17. A lozengeof claim 16, wherein said lozenge comprises nicotine or a salt thereof.18. A method of treating nicotine or tobacco dependence, said methodcomprising administering to a patient in need to such treatment thelozenge of claim
 17. 19. The process of claim 2, wherein said powderblend comprises from about 50 to about 99.9 percent, by weight, of saidamorphous carbohydrate polymer.
 20. The process of claim 3, wherein saidpowder blend comprises from about 50 to about 99.9 percent, by weight,of said amorphous carbohydrate polymer.
 21. The process of claim 5,wherein said powder blend comprises from about 50 to about 99.9 percent,by weight, of said amorphous carbohydrate polymer.
 22. The process ofclaim 11, wherein said powder blend comprises from about 50 to about99.9 percent, by weight, of said amorphous carbohydrate polymer.
 23. Theprocess of claim 13, wherein said powder blend comprises from about 50to about 99.9 percent, by weight, of said amorphous carbohydratepolymer.
 24. The process of claim 3, wherein said at least one saidforming tool emits said radiofrequency energy to said shape.
 25. Theprocess of claim 5, wherein said at least one said forming tool emitssaid radiofrequency energy to said shape.
 26. The process of claim 7,wherein said at least one said forming tool emits said radiofrequencyenergy to said shape.
 27. The process of claim 19, wherein said at leastone said forming tool emits said radiofrequency energy to said shape.28. The process of claim 20, wherein said at least one said forming toolemits said radiofrequency energy to said shape.
 29. The process of claim21, wherein said at least one said forming tool emits saidradiofrequency energy to said shape.